Assembly comprising a carrier part and a ball joint housing

ABSTRACT

An assembly comprises a carrier part and a ball joint housing. The housing is provided with an attachment projection which is formed integrally with the housing on an outer surface of the housing. The carrier part is formed as a double-layer structure, and the attachment projection is held between two layers of the carrier part.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a National Stage of International Application No.PCT/EP2006/011723 filed Dec. 6, 2006, the disclosures of which areincorporated herein by reference in entirety, and which claimed priorityto German Patent Application No. 10 2006 008 252.4 filed Feb. 22, 2006,the disclosures of which are incorporated herein by reference inentirety.

BACKGROUND OF THE INVENTION

The invention relates to an assembly comprising a carrier part and aball joint housing. The invention in particular relates to a vehiclesuspension part having a ball joint housing attached thereto.

In order to fasten a ball joint to a stamped sheet metal vehiclesuspension part such as a chassis link control arm, it is known to forgea flange onto a housing of the ball joint and to fasten this flange tothe suspension part by means of rivets or screws. A disadvantage here isthe comparatively great effort in installation as well as overallcomponent costs, specifically the forged housing.

BRIEF SUMMARY OF THE INVENTION

A feature of the invention consists in providing an assembly comprisinga carrier part and a ball joint housing which allows to securely attachthe ball joint housing with reduced costs and where only a smallclearance space is available.

In order to solve this feature, the invention provides an assemblycomprising a carrier part and a ball joint housing, the housing beingprovided with an attachment projection which is formed integrally withthe housing on an outer surface of the housing, wherein the carrier partis formed as a double-layer structure and the attachment projection isheld between two layers of the carrier part. This design allows tosecurely attach the ball joint housing as it is held between two layersof the carrier part, and further allows to meet tight space requirementsas the weld seams for attaching the ball joint housing can be made wherespace is available, e.g. spaced from the ball joint housing or directlybetween the attachment projection and the carrier part.

According to one embodiment, the attachment projection is constructed asa collar, in particular as annular collar which encircles the ball jointhousing. The collar allows to optimize the transfer of forces betweenthe ball joint housing and the carrier part whereby low stresses occur.

According to one embodiment, the ball joint housing has a receivingspace for a ball stud which has a central axis, the annular collardefining a plane which is perpendicular to the central axis of thereceiving space. Each point of the attachment projection therefore hasthe same distance from the upper edge and the lower edge of the housing,respectively. If the attachment projection is encircling, the housing isconstructed so as to be rotationally symmetrical and therefore itsproduction is simpler and cheaper. If the ball joint is to be attachedinclined with respect to the general plane of extent of the carrierpart, the two layers of the carrier part are bent adjacent the balljoint housing.

According to an alternative embodiment, the ball joint housing has areceiving space for a ball stud which has a central axis, the annularcollar defining a plane which is oblique to the central axis of thereceiving space. In order to mount the ball joint to the carrier part ata particular inclination, it was necessary hitherto to bend the carrierpart adjacent to the housing differently according to the side of use onthe vehicle. Now, a ball joint can be fitted with a differentinclination both to the left-hand and to the right-hand carrier part ofthe vehicle, because of the attachment projection. The carrier parts cantherefore be constructed identically for both sides, allowing costsavings.

The attachment projection can be extrusion-molded, forged or integrallyformed with the ball joint housing in any other suitable manner so thatthe effort for forming a separate attachment provision is avoided.

According an one embodiment, the attachment projection is provided withtwo weld surfaces which are arranged on opposite sides thereof and whichare welded to the carrier part. The most essential advantage of thissolution consists in that a good transfer of force is possible owing tothe large weld surface. In addition, lower costs are incurred, comparedwith the prior art.

According to an embodiment of the invention, the layers are connected tothe weld surfaces of the attachment projection by capacitor dischargewelding. In the capacitor discharge welding process, a high currentflows only for a short period of time between the housing and thecarrier part. During this, the material heats up locally in the regionof its contact surfaces such that the materials weld to each other. Theamount of heat released during the welding process is so small that forexample a sealing bellows which is provided adjacent the weldingsurfaces is not impaired.

According to an alternative embodiment, the double-layer structure isformed from the carrier part as such and a reinforcement part which isattached to the carrier part so as to clamp the attachment projectionbetween the carrier part and the reinforcement part. This allows to usea standard welding process such as MIG welding since the surfaces to bewelded to each other are accessible.

Depending on the space available and the loads to be transferred betweenthe carrier part and the ball joint housing, the reinforcement part iswelded to the carrier part, the ball joint housing is welded to thecarrier part, and/or the ball joint housing is welded to thereinforcement part.

According to a preferred embodiment, the carrier part is a bent sheetmetal part, in particular a suspension arm of a motor vehicle.

Other advantages of this invention will become apparent to those skilledin the art from the following detailed description of the preferredembodiments, when read in light of the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a cross-section through an assembly with a ball jointhousing and a carrier part according to a first embodiment of theinvention;

FIG. 2 shows a cross-section through an assembly with a ball jointhousing and a carrier part according to a second embodiment of theinvention;

FIG. 3 shows a cross-section through an assembly with a ball jointhousing and a carrier part according to a third embodiment of theinvention;

FIG. 4 shows a cross-section through an assembly with a ball jointhousing and a carrier part according to a fourth embodiment of theinvention;

FIG. 5 shows a general perspective view of the assemblies of FIGS. 1 to3;

FIG. 6 shows a cross-section through an assembly with a ball jointhousing and a carrier part according to a fifth embodiment of theinvention,

FIG. 7 shows a perspective view of the assembly of FIG. 6;

FIG. 8 shows a cross-section through an assembly according to a sixthembodiment of the invention;

FIG. 9 shows the assembly according to the sixth embodiment in a firstperspective view;

FIG. 10 shows the assembly according to the sixth embodiment in a secondperspective view;

FIG. 11 shows a first step of assembling the assembly according to thesixth embodiment;

FIG. 12 shows a second step of assembling the assembly according to thesixth embodiment;

FIG. 13 shows a third step of assembling the assembly according to thesixth embodiment;

FIG. 14 shows a fourth step of assembling the assembly according to thesixth embodiment; and

FIG. 15 shows a fifth step of assembling the assembly according to thesixth embodiment.

DETAILED DESCRIPTION OF THE INVENTION

A first embodiment of an assembly comprising a ball joint 10 and acarrier part 12 will be described with reference to FIGS. 1 and 5.

Carrier part 12 is part of the vehicle suspension system, in particulara control arm connecting a wheel carrier to the vehicle chassis or body.The carrier part is made from sheet metal and is formed at least in theregion in which ball joint 10 is to be attached as a double-layerstructure having two layers 22. Both layers 22 are provided with acircular recess 14 which is to accommodate the ball joint housing 16.The carrier part may be provided with a sleeve 40 and a cylinder 42which are secured the carrier part and which serve for fastening thecarrier part to the vehicle body.

The ball joint 10 has a housing 16 which is provided with an attachmentprojection 18 which is formed integrally with the ball joint housing 10,preferably by forging, flow-pressing or molding. Here, the attachmentprojection is formed as an annular ring which encircles ball jointhousing 16. The plane in which the ring lies is parallel to the plane ofextent of the layers 22 and perpendicular to a central axis A of theball joint 10. As can be seen in FIG. 1, the diameter of recess 14 isslightly greater than the external diameter of the ball joint housing16, but less than the outer diameter of the attachment projection 18.

Ring-shaped attachment projection 18 is provided with two circularbosses 36 lying opposite each other. In other words, a first circularboss extends on the upper side of the attachment projection around itscircumference, and a second circular boss extends on the lower side ofthe attachment projection around its circumference.

In a manner known per se, the interior of the ball joint housing 16receives a ball stud 24 in a receiving space 26 such that the ball studcan be swiveled relative to ball joint housing 16 by a certain angle.

A sealing bellows 28 is secured to ball joint housing 16 by means of afirst, upper clamping ring 30 and to a stud portion 32 of the ball stud24 by means of a second, lower clamping ring 34. It protects the balljoint 10 from dirt and humidity. The ball stud 24 can either beintroduced into the ball joint housing 16 before it is arranged with therecess 14 in the carrier part 12 or can be introduced after the weldingof the ball joint housing 16 to the carrier part 12.

To secure the ball joint 10 to the carrier part 12, particularly to thelayers 22 of the carrier part 12, ball joint housing 16 is placed withinrecesses 14 in the carrier part 12 such that the attachment projection18 lies between the two layers 22. A capacitor discharge welding methodin which a high current flows for a short period of time between balljoint housing 16 and the carrier part 12, is particularly suitable forconnecting the attachment projection 18 with the carrier part 12. Thisprocess results in locally heating the material in the region of contactbetween the circular lugs 36 on the attachment projection 18 and theassociated surfaces of the carrier part 12, these region of contactforming two circular weld surfaces 20 at which the material of the balljoint housing and the carrier part weld to each other. A weld seam istherefore formed on opposite sides to each other of the attachmentprojection 18, which produces the inter-material bond between thehousing 16 and the carrier part 12. Due to the shape of the attachmentprojection, two circular weld seams are formed which provide for uniformand reliable connection which allows to transfer high loads. As can beseen in FIG. 1, central axis A is perpendicular to the plane in whichlayers 22 of carrier part 12 extend.

A protection of the ball joint 10 and of the carrier part 12 againstcorrosion may be applied jointly after welding.

As an alternative design, the layers 22 could be formed so as to notextend continuously around ball joint housing 16 but be formed so as tohave a couple of segments. Then, the weld surface 20 would be formed inan interrupted manner.

A second embodiment is shown in FIG. 2. For the elements known from thefirst embodiment, the same reference numerals are used, and reference ismade in this respect to the above comments.

The difference between the first and the second embodiment is that inthe second embodiment, attachment projection 18 is formed chamfered onboth sides. This results in that weld surfaces 20 are formed ring-shapedadjacent ball joint housing 16.

A third embodiment is shown in FIG. 3. For the elements known from thefirst and second embodiments, the same reference numerals are used, andreference is made in this respect to the above comments.

The difference between the first embodiment and the third embodiment isthat in the third embodiment, the sealing bellows 28 here has a clampingsection 38 which is constructed as an encircling flange which istriangular when viewed in cross-section. The flange lies against theattachment projection 18 which is provided with the lugs 36, and isclamped particularly between the lower layer 22 of carrier part 12, theattachment projection 18 and the ball joint housing 16 such that it isreliably held there. The clamping ring 30 which is shown could thereforebe dispensed with in this embodiment.

A fourth second embodiment is shown in FIG. 4. For the elements knownfrom the third embodiment, the same reference numerals are used, andreference is made in this respect to the above comments.

The difference between the third and the fourth embodiment is that inthe fourth embodiment, attachment projection 18 extending around balljoint housing 16 is arranged obliquely with respect to the central axisA. In other words, the distance between the upper edge of the housing 16and the attachment projection changes, and ball joint housing 16 is notrotationally symmetrical. In the mounted condition, central axis Athrough receiving space 26 of ball joint housing 16 is oblique to theplane of layers 22. The ball joint 10 is therefore welded to layers 22at a particular inclination which can be varied through the constructionof the attachment projection 18.

A fifth embodiment is shown in FIGS. 6 and 7. For the elements knownfrom the fourth embodiment, the same reference numerals are used, andreference is made in this respect to the above comments.

The difference between the fourth embodiment and fifth embodiment isthat in the fifth embodiment, attachment projection 18 does not extendaround the entire housing but only along a portion which is less than180°. Correspondingly, recess 14 in layers 22 of carrier part 12 has theshape of a circular segment. As the layers 22 do not fully surround thehousing 16, this embodiment may be optimally adapted to conditions wherespace is restricted.

At the ends of the attachment projection 18, the layers 22 extend overthe attachment projection in an alternating manner. The upper layerextends over the attachment projection on one side so that it can bebent downwardly towards the lower layer, and the lower layer extendsover the attachment projection on the opposite side so that it can bebent upwardly towards the upper layer. Accordingly, the attachmentprojection is embraced (please see FIG. 7). The bent ends are thenwelded to the respective other layer such that weld seams 44 arecreated. In addition, the two layers 22 are additionally welded to eachother in their marginal region (please see weld seam 37 in FIG. 7).

In the installed state, the central axis A through receiving space 26 ofthe housing is oblique to the plane of layers 22. However, the centralaxis A could also be perpendicular to the plane of layers 22 in analternative embodiment which is not shown.

In order to attach the ball joint 10 to the carrier part 12 at aparticular inclination, the embodiments of FIGS. 1 to 3 require to bendlayers 22 adjacent ball joint 10 differently, depending on which side ofthe vehicle the respective carrier part is to be installed. The balljoint 10 shown in FIGS. 4 and 6 however can be attached differentlyinclined both at the left carrier part and also at the right carrierpart of the vehicle, due to the inclination of attachment projection 18.The carrier parts 12 as such can therefore be manufactured identicallyfor the two sides.

An assembly according to a sixth embodiment is shown in FIGS. 8 to 10.For the elements known from the previous embodiments, the same referencenumerals will be used, and reference is made in this respect to theabove comments.

Here again, the carrier part 12 is part of a vehicle suspension controlarm which is made from stamped sheet metal. It has a generally U-shapedcross section with a base 52, an inner leg 54 and an outer leg 56. Inthe region of ball joint 10, outer leg 56 is interrupted so as toprovide a clearance to adjacent components of the wheel carrier. Balljoint housing 16 is provided with attachment projection 18 which isformed as a ring which extends around the circumference of the housing.

The main difference between the sixth embodiment and the previousembodiments is that in the sixth embodiment, ball joint housing 16 isattached to carrier part 12 not by welding attachment projection 18 tothe carrier but by clamping attachment projection 18 between a first anda second layer of the carrier part. In particular, attachment projection18 is securely held between base 52 of carrier part 12 and areinforcement part 50 fixed to the carrier part. Reinforcement part 50is a stamped sheet metal part which is formed separately from carrierpart 12 and which is arranged between legs 54, 56 of the carrier part.

As can be seen in FIG. 11, both the base 52 of the carrier part 12 andthe reinforcement part 50 are formed with a recess 14. The innerdiameter of recess 14 basically corresponds to the outer diameter ofball joint housing 16 so that the ball joint housing is held thereinwithout play.

As can be seen in FIGS. 12 and 13, the reinforcement part 50, the balljoint housing 16 and the carrier part 12 are assembled such thatattachment projection 18 is arranged between base 52 of carrier part 12and reinforcement part 50, and reinforcement part 50 is arranged betweenlegs 54, 56 of carrier part 12.

As is shown in FIG. 14, reinforcement part 50 is connected to inner leg54 of carrier part 12 by means of a weld seam 60, and to outer leg 56 bymeans of two weld seams 62.

As can be seen in FIG. 15, ball joint housing 16 is connected to base 52of carrier part 12 by means of a weld seam 64 which is arranged on thelower side of base 52.

All weld seams 60, 62, 64 can be made with a conventional weldingprocess such as MIG welding or similar fusion welding processes.

In accordance with the provisions of the patent statutes, the principleand mode of operation of this invention have been explained andillustrated in its preferred embodiments. However, it must be understoodthat this invention may be practiced otherwise than as specificallyexplained and illustrated without departing from its spirit or scope.

1. A vehicle suspension assembly comprising: a ball joint housing havingan interior receiving space for swivelably supporting a ball stud in theball joint housing, the ball joint housing having an attachmentprojection which is formed integrally with the ball joint housing on acylindrical outer surface thereof, the attachment projection beingformed as an annular collar which encircles the ball joint housing andwhich extends radially outwardly from the ball joint housing; and asuspension control arm comprising a carrier part for connecting a wheelcarrier to a vehicle chassis, the carrier part having fastening meansfor fastening the carrier part to the vehicle chassis and being formedas a double-layer structure comprising spaced apart opposing first andsecond plates, each of the first and second plates having a throughopening for receiving the ball joint housing, the through openings beingaxially aligned; wherein the cylindrical outer surface of the ball jointhousing is concentrically arranged within each respective throughopening of the first and second plates, and the attachment projection issandwiched between spaced apart opposing inner surfaces of the first andsecond plates of the carrier part such that the cylindrical outersurface of the ball joint housing is spaced from an edge of the throughopenings; wherein the attachment projection is provided with twoopposing annular weld surfaces which are arranged on opposite sides ofthe annular collar and which are welded to the opposing inner surfacesof the first and second plates of the carrier part; and wherein thethrough openings of the first and second plates are each defined by anenclosed circular opening or an open recess in the form of a circularsegment along an edge of each respective plate.
 2. The assembly of claim1 wherein the receiving space has a central axis, the annular collardefining a plane which is perpendicular to the central axis of thereceiving space.
 3. The assembly of claim 2 wherein the central axis ofthe ball joint housing is perpendicular to a plane of the first andsecond plates of the carrier part.
 4. The assembly of claim 1 whereinthe receiving space has a central axis, the annular collar defining aplane which is oblique to the central axis of the receiving space. 5.The assembly of claim 4 wherein the central axis of the ball jointhousing stands obliquely on a plane of the first and second plates ofthe carrier part.
 6. The assembly of claim 1 wherein the attachmentprojection is flow-pressed.
 7. The assembly of claim 1, wherein theopposing inner surfaces of the first and a second plates are connectedto the weld surfaces of the attachment projection by capacitor dischargewelding.
 8. The assembly of claim 1 wherein the carrier part is a bentsheet metal part.
 9. The assembly of claim 1 wherein each throughopening of the carrier part defines a circular opening having a diameterwhich is greater than an external diameter of the ball joint housingsuch that the two plates of the carrier part are configured to holdtherebetween only the attachment projection of the housing.
 10. Avehicle suspension assembly comprising: a ball joint housing having aninterior receiving space for swivelably supporting a ball stud in theball joint housing, the ball joint housing having an attachmentprojection which is formed integrally with the ball joint housing on acylindrical outer surface thereof, the attachment projection beingformed as an annular collar which encircles the ball joint housing andwhich extends radially outwardly from the ball joint housing; and asuspension control arm comprising a carrier part for connecting a wheelcarrier to a vehicle chassis and a reinforcement part attached to thecarrier part, the carrier part having fastening means for fastening thecarrier part to the vehicle chassis, a double-layer structure beingformed by a first plate of the carrier part and a spaced apart opposingsecond plate of the reinforcement part, each of the first and secondplates having a through opening for receiving the ball joint housing,the through openings being axially aligned; wherein the cylindricalouter surface of the ball joint housing is concentrically arrangedwithin each respective through opening of the first and second plates,and the attachment projection is sandwiched between spaced apartopposing inner surfaces of the first and second plates of the carrierpart and the reinforcement part such that the cylindrical outer surfaceof the ball joint housing is spaced from an edge of the throughopenings; wherein the attachment projection is provided with twoopposing annular weld surfaces which are arranged on opposite sides ofthe annular collar and which are welded to the opposing inner surfacesof the first and second plates of the carrier part and the reinforcementpart; and wherein the through openings of the first and second platesare each defined by an enclosed circular opening or an open recess inthe form of a circular segment along an edge of each respective plate.11. The assembly of claim 10 wherein the reinforcement part is welded tothe carrier part.
 12. The assembly of claim 10 wherein each throughopening of the carrier part and the reinforcement part defines acircular opening having a respective diameter which is greater than anexternal diameter of the ball joint housing such that the two plates ofthe carrier part and the reinforcement part are configured to holdtherebetween only the attachment projection of the housing.